Photovoltaic module having bi-directional couplings

ABSTRACT

Photovoltaic module systems are provided. These systems can comprise multiple photovoltaic laminates connected with one or more mechanical coupling pairs that extend beyond perimeter edges of individual photovoltaic laminates. The mechanical coupling pairs can be connected to ends of support members positioned beneath the photovoltaic laminates. During assembly, an additional photovoltaic laminate may be added to connected photovoltaic laminates that are previously connected and lie along a shared plane of reference via pairs of mechanical couplings.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/984,742, filed on Aug. 4, 2020, and now U.S. Pat. No. 11,239,791,which issued Feb. 1, 2022. The '742 application is a continuation ofU.S. patent application Ser. No. 16/006,444, filed on Jun. 12, 2018, andnow U.S. Pat. No. 10,763,780, which issued on Sep. 1, 2020. The '444application claims the benefit of U.S. Provisional Application No.62/525,142, filed on Jun. 26, 2017, the entire contents of which arehereby incorporated by reference herein.

BACKGROUND

Photovoltaic (PV) cells, commonly known as solar cells, are well knowndevices for converting solar radiation into electrical energy.Generally, solar cells are fabricated on a semiconductor wafer orsubstrate using semiconductor processing techniques to form a p-njunction near a surface of the substrate. Solar radiation impinging onthe surface of the substrate creates electron and hole pairs in the bulkof the substrate, which migrate to p-doped and n-doped regions in thesubstrate, thereby generating a voltage differential between the dopedregions. The doped regions are coupled to metal contacts on the solarcell to direct an electrical current from the cell to an externalcircuit coupled thereto. Generally, an array of solar cells, each solarcell interconnected, is mounted on a common or shared platform toprovide a PV module. For example, a PV module may include an array ofsolar cells in a PV laminate. Several PV modules or module groups may beelectrically coupled to an electrical power distribution network,forming a PV system.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a photovoltaic panel supported along an outer edge.

FIG. 2 illustrates a perspective view of a photovoltaic module assemblyhaving bi-directionally connected photovoltaic modules, in accordancewith an embodiment of the present disclosure.

FIG. 3 illustrates a cross-sectional view, taken about line 3-3 of FIG.2 , of a photovoltaic laminate, in accordance with an embodiment of thepresent disclosure.

FIG. 4 illustrates a back perspective view of a photovoltaic moduleassembly having bi-directionally connected photovoltaic modules, inaccordance with an embodiment of the present disclosure.

FIG. 5 illustrates a back view of a photovoltaic module havingbi-directional couplings, in accordance with an embodiment of thepresent disclosure.

FIG. 6 illustrates a back view of a corner region of a photovoltaicmodule having bi-directional couplings, in accordance with an embodimentof the present disclosure.

FIG. 7 illustrates a perspective view of a male coupling, in accordancewith an embodiment of the present disclosure.

FIG. 8 illustrates a side view of a male coupling, in accordance with anembodiment of the present disclosure.

FIG. 9 illustrates a cross-sectional view, taken about line 9-9 of FIG.8 , of a male coupling, in accordance with an embodiment of the presentdisclosure.

FIG. 10 illustrates a top view of a male coupling, in accordance with anembodiment of the present disclosure.

FIG. 11 illustrates a perspective view of a female coupling, inaccordance with an embodiment of the present disclosure.

FIG. 12 illustrates a side view of a female coupling, in accordance withan embodiment of the present disclosure.

FIG. 13 illustrates a cross-sectional view, taken about line 13-13 ofFIG. 12 , of a female coupling, in accordance with an embodiment of thepresent disclosure.

FIG. 14 illustrates a top view of a female coupling, in accordance withan embodiment of the present disclosure.

FIGS. 15A-15C illustrate a male coupling connecting to a female couplingusing a first locking mode, in accordance with an embodiment of thepresent disclosure.

FIGS. 16A-16B illustrate a male coupling connecting to a female couplingusing a second locking mode, in accordance with an embodiment of thepresent disclosure.

FIG. 17 illustrates a flowchart of a method of assembling a photovoltaicmodule assembly having bi-directionally connected photovoltaic modules,in accordance with an embodiment of the present disclosure.

FIGS. 18A-18C illustrate operations in a method of assembling aphotovoltaic module assembly having bi-directionally connectedphotovoltaic modules, in accordance with an embodiment of the presentdisclosure.

FIG. 19 illustrates a perspective view of a rail coupler, in accordancewith an embodiment of the present disclosure.

FIG. 20 illustrates a cross-sectional view of a support rail, inaccordance with an embodiment of the present disclosure.

FIG. 21 illustrates a perspective view of a corner region of aphotovoltaic module having a stackable edge protector, in accordancewith an embodiment of the present disclosure.

DETAILED DESCRIPTION

The following detailed description is merely illustrative in nature andis not intended to limit the embodiments of the subject matter or theapplication and uses of such embodiments. As used herein, the word“exemplary” means “serving as an example, instance, or illustration.”Any implementation described herein as exemplary is not necessarily tobe construed as preferred or advantageous over other implementations.Furthermore, there is no intention to be bound by any expressed orimplied theory presented in the preceding technical field, background,brief summary or the following detailed description.

This specification includes references to “one embodiment” or “anembodiment.” The appearances of the phrases “in one embodiment” or “inan embodiment” do not necessarily refer to the same embodiment.Particular features, structures, or characteristics can be combined inany suitable manner consistent with this disclosure.

Terminology. The following paragraphs provide definitions and/or contextfor terms found in this disclosure (including the appended claims):

“Comprising.” This term is open-ended. As used in the appended claims,this term does not foreclose additional structure or steps.

“Configured To.” Various units or components may be described or claimedas “configured to” perform a task or tasks. In such contexts,“configured to” is used to connote structure by indicating that theunits/components include structure that performs those task or tasksduring operation. As such, the unit/component can be said to beconfigured to perform the task even when the specified unit/component isnot currently operational (e.g., is not on/active). Reciting that aunit/circuit/component is “configured to” perform one or more tasks isexpressly intended not to invoke 35 U.S.C. § 112, sixth paragraph, forthat unit/component.

“First,” “Second,” etc. As used herein, these terms are used as labelsfor nouns that they precede, and do not imply any type of ordering(e.g., spatial, temporal, logical, etc.). For example, reference to a“first” edge does not necessarily imply that this edge is the first edgein a sequence; instead the term “first” is used to differentiate thisedge from another edge (e.g., a “second” edge).

“Coupled”—The following description refers to elements or nodes orfeatures being “coupled” together. As used herein, unless expresslystated otherwise, “coupled” means that one element/node/feature isdirectly or indirectly joined to (or directly or indirectly communicateswith) another element/node/feature, and not necessarily mechanically.

In addition, certain terminology may also be used in the followingdescription for the purpose of reference only, and thus are not intendedto be limiting. For example, terms such as “upper,” “lower,” “above,”“below,” “in front of,” and “behind” refer to directions in the drawingsto which reference is made. Terms such as “front,” “back,” “rear,”“side,” “outboard,” “inboard,” “leftward,” and “rightward” describe theorientation and/or location of portions of a component, or describe therelative orientation and/or location between components, within aconsistent but arbitrary frame of reference which is made clear byreference to the text and the associated drawings describing thecomponent(s) under discussion. Such terminology may include the wordsspecifically mentioned above, derivatives thereof, and words of similarimport.

“Inhibit”—As used herein, inhibit is used to describe a reducing orminimizing effect. When a component or feature is described asinhibiting an action, motion, or condition it can completely prevent theresult or outcome or future state completely. Additionally, “inhibit”can also refer to a reduction or lessening of the outcome, performance,and/or effect which might otherwise occur. Accordingly, when acomponent, element, or feature is referred to as inhibiting a result orstate, it need not completely prevent or eliminate the result or state.

Referring to FIG. 1 , a photovoltaic module having a photovoltaic panelsupported along an outer edge is illustrated. Existing PV modules 100include support frames 102 supporting a PV panel 106 along an outer edge104. Support frames 102 can be mounted on an external structure 108,e.g., a rooftop. Thus, when environmental loading is applied to the PVpanel 106, e.g., by pressing downward on PV panel 106, externalstructure 108 transmits an upward reactive force through support frames102 to outer edges 104. Accordingly, the environmental load iscounteracted by a reactive force distributed along outer edges 104, andPV laminate 106 between outer edges 104 acts like an end-supported beam.That is, PV panel 106 sags under the downward force applied by theenvironmental loading. More particularly, PV panel 106 can deflect tovarying degrees between the supports at outer edges 104. For example, PVpanel 106 can have a support deflection, which is an area of minimumdeflection, near outer edges 104. Further from outer edges 104, PV panel106 can have a design deflection. The design deflection can be adeflection having a predetermined factor of safety compared to a maximumdeflection that PV laminate 106 may experience prior to cracking. Atlocations even further from outer edges 104, PV laminate 106 can deflectby the maximum deflection. The maximum deflection can be a deflection atwhich cracking is statistically likely to occur in PV panel 106. Themaximum deflection can correspond to a design load pressing on PV panel106. By way of example, the design load can be a 6000 Pascal pressureacross a face of PV panel 106. The design load can correspond to auniform snowfall. Real-world loading can, however, differ from thedesign load, and thus, PV panel 106 can deflect to an over deflection atone or more locations between outer edges 104. The over deflection canbe a deflection at which cracking occurs in PV module 106.

To reduce a likelihood of over defection and cracking, PV panel 106 caninclude a glass-glass laminate having a predetermined thickness. Forexample, to reduce the likelihood of over deflection in PV panel 106,the glass-glass laminate can be formed with glass sheets havingthicknesses less than 3 mm. Such PV panels 106, however, can be costlyboth to manufacture and to ship to an installation site. Furthermore,glass-glass laminate modules can be particularly difficult to installbecause handling damage may be more likely to occur. Thus, a lighter PVpanel capable of resisting cracking under environmental loading, canprovide an improvement over the state of the art.

In an aspect, a PV module assembly, e.g., a residential module system,that is economical, reliable, and easy to install, is provided. The PVmodule assembly can include PV modules having PV laminates incorporatinga front glass sheet and a rear polymer sheet that is less costly tomanufacture and ship, as compared to a glass-glass laminate. Forexample, the PV laminate may incorporate thinner glass, and thus, may belarger and lighter than existing PV panels. To avoid mechanical failureand/or cracking of the larger, lighter PV laminate, the PV moduleassembly can include a support frame that supports the PV panel across aback surface of the rear polymer sheet. The support frame can have ahash profile. Thus, the PV laminate can have a decreased support span,e.g., between lines of the hash profile, that in turn reduces adeflection of the PV laminate, and reduces a likelihood that PV cellswithin the PV laminate will crack.

In an aspect, the support frames supporting each PV laminate in the PVmodule assembly can include bi-directional couplings to attach toadjacent support frames. The PV modules of the assembly can beinterconnected in two directions, e.g., in an x-direction and in ay-direction. The bi-directional couplings can include snap and/ortongue-and-groove mechanisms that assemble quickly with no added toolsto form tool-less connections, and make installation easier to perform.Furthermore, the interconnected PV modules can support each other indifferent directions to share loading. The load sharing can reduce arequired number of connection points to an external mounting structure,such as a roof, as compared to existing PV module assemblies.

The aspects described above can be realized by the PV module havingbi-directional couplings as disclosed herein. In the followingdescription, numerous specific details are set forth, such as specificmaterial regimes and component structures, in order to provide athorough understanding of embodiments of the present disclosure. It willbe apparent to one skilled in the art that embodiments of the presentdisclosure may be practiced without these specific details. In otherinstances, well-known fabrication techniques or component structures,such as specific types of mechanical couplings or techniques forlaminating PV module components, are not described in detail in order tonot unnecessarily obscure embodiments of the present disclosure.Furthermore, it is to be understood that the various embodiments shownin the figures are illustrative representations and are not necessarilydrawn to scale.

By way of summary, disclosed herein is a PV module assembly and a PVmodule having bi-directional couplings. In an embodiment, a PV moduleincludes a PV laminate extending along a lateral plane within aperimeter. The PV module includes a support frame mounted under thephotovoltaic laminate. The support frame includes a first support railextending longitudinally in a first direction to a first outward end,and a second support rail extending longitudinally in a second directionto a second outward end. The first direction is orthogonal to the seconddirection. The support frame further includes a first coupling mountedon the first outward end, and a second coupling mounted on the secondoutward end. The first coupling and the second coupling can be malecouplings and/or female couplings, and can form male-to-femaleconnections with couplings of an adjacent PV module.

In an embodiment, a PV module assembly includes a keystone module havinga support frame including a first coupling under a first edge of aperimeter and a second coupling under a second edge of the perimeter. Afirst lateral module is mounted on the first coupling, and a secondlateral module is mounted on the second coupling. The lateral modulesare coupled to the keystone module by male-to-female connections.

In an embodiment, a method of fabricating a PV module assembly havingbi-directional couplings includes attaching a first lateral module to afirst coupling of a keystone module. The method includes attaching asecond lateral module to a second coupling of the keystone module. Themodules can be mounted on an external support structure, e.g., a roof,by brackets. In an embodiment, the keystone module is attached to theroof by a greater number of brackets than a number of brackets used toattach the first lateral module and/or the second lateral module to theroof.

Referring to FIG. 2 , a perspective view of a photovoltaic moduleassembly having bi-directionally connected photovoltaic modules is shownin accordance with an embodiment of the present disclosure. A PV moduleassembly 200 can include one or more PV modules 202 interconnected inseveral directions. For example, PV module assembly 200 can include akeystone module 204 connected to a first lateral module 206 in anx-direction 208, and keystone module 204 can be connected to a secondlateral module 210 in a y-direction 212. “Keystone” module 204 may beso-termed because keystone module 204 may be a first module mounted inan array of modules, and other modules may be mounted on and/or aroundkeystone module 204. The other modules, e.g., first lateral module 206and second lateral module 210, may rely on keystone module 204 forsupport. Keystone module 204 may be termed differently, e.g., as ananchor module, a primary module, or a principal module. Keystone module204 may be an anchor module because keystone module 204 may providestrength or support to other modules in the module array. Keystonemodule 204 may be a primary module or a principal module becausekeystone module 204 may be a first module mounted on an external supportstructure when installing the module array.

As described below, each PV module 202 of PV module assembly 200 canhave one or more couplings (not shown) to attach the PV module to anadjacent PV module. For example, first lateral module 206 can be mountedon a first coupling of keystone module 204 and second lateral module 210can be mounted on a second coupling of keystone module 204. Eachcoupling can connect support frames of the PV modules together.Accordingly, PV module assembly 200 can include a supporting web ofinterconnected PV modules 202, and the interconnected modules can shareloading and distribute a downward force on an external mountingstructure. For example, as described below, PV module assembly 200 canbe supported by a roof, and can transmit loading forces to the roofthrough mounting brackets attached to an underlying support frame.Accordingly, the support frame (and brackets) can hold PV modules 202above the external mounting structure.

Each PV module 202 in PV module assembly 200 can have a samearchitecture. For example, each PV module 202 can include a PV laminate214 having one or more PV cells 216. PV cells 216 can be arranged in agrid, i.e., several row(s) or columns(s), inward from the outer edges ofPV module 202. More particularly, PV cells 216 can be electricallyconnected in one or more PV cell strings laterally inward from the outeredges of PV laminate 214. The outer edges of PV laminate 214 can definea perimeter of PV module 202 around PV cells 216. A combination ofoutward facing edges of several PV module perimeters in PV moduleassembly 200 can define an outer perimeter 218 of PV module assembly200.

Referring to FIG. 3 , a cross-sectional view, taken about line 3-3 ofFIG. 2 , of a photovoltaic laminate is shown in accordance with anembodiment of the present disclosure. PV laminate 214 can include alaminated structure that includes several PV cells 216 between a frontlayer 302 and a back layer 306. For example, PV cell 216 can beencapsulated between front layer 302 and back layer 306, and anencapsulant 308 can be laminated over PV cell 216 between both frontlayer 302 and back layer 306. Encapsulant 308 can be a material havingexcellent adhesion and light transmission characteristics. For example,encapsulant 308 can include a thermoplastic olefin, e.g., polyethylene.Accordingly, encapsulant 308 can bond PV cell 216 to front layer 302 andback layer 306, and can permit light to transmit through front layer 302or back layer 306 to be captured by PV cell 216 for energy conversion.

Front layer 302 and back layer 306 can be coextensive along paralleltransverse planes. More particularly, front layer 302 and back layer 306can extend along a lateral plane 310 in a transverse direction, e.g., ahorizontal direction. Accordingly, PV laminate 214 can extend alonglateral plane 310 within a PV module perimeter. Front layer 302 of PVlaminate 214 can have a front surface 312 extending transversely betweenopposite edges of a PV module perimeter, and back layer 306 can have aback surface 314 extending transversely between the opposite edges ofthe PV module perimeter.

In an embodiment, front layer 302 includes a sheet of transparentmaterial. By way of example, front layer 302 can include a glass sheet.Furthermore, PV cell 216 can include a cell surface facing upward toreceive sunlight through front layer 302. Accordingly, sunlight cantransmit through front layer 302 to PV cell 216 for energy conversion.

In an embodiment, front layer 302 and back layer 306 are formed fromdifferent materials. By way of example, front layer 302 can include aglass sheet and back layer 306 can include a polymer sheet. As such,front layer 302 and back layer 306 can have different elastic modulus.More particularly, front layer 302 can be formed from a first materialhaving a first modulus, and back layer 306 can be formed from a secondmaterial having a second modulus. Such a laminate structure can bereferred to as an asymmetric laminate structure. In an embodiment, thelayers of the asymmetric laminate structure are apt to deflectdifferently under an external load. For example, the asymmetric laminatestructure can distribute stresses disproportionately throughout thelaminate cross-section, and thus, the asymmetric laminate structure canflex more under a given load than a typical glass-glass module.Accordingly, the asymmetric laminate structure can benefit from aninterconnected support structure that supports back surface 314 of PVlaminate 214.

Although front layer 302 and back layer 306 can include differentelastic moduli, the layers can alternatively include a same elasticmodulus. For example, front layer 302 and back layer 306 can be formedof a same material, e.g., glass-glass or polymer-polymer. In the case ofPV module 202 having a polymeric front layer 302 and a polymeric backlayer 306, PV module 202 can be a flexible panel. PV module 202 cannonetheless be adequately supported by an interconnected supportstructure to provide a lightweight and robust PV laminate 214.

Referring to FIG. 4 , a back perspective view of a photovoltaic moduleassembly having bi-directionally connected photovoltaic modules is shownin accordance with an embodiment of the present disclosure. Theinterconnected support structure holding PV modules 202 of PV moduleassembly 200 can include several support frames 402 mounted onrespective PV laminates 214. For example, the keystone module 204 caninclude a first support frame 402 mounted on a first PV laminate 214,and first lateral module 206 can include a second support frame 402mounted on a second PV laminate 214. Each support frame 402 can beconnected to an adjacent support frame 402 by one or more male-to-femaleconnections 404. For example, keystone module 204 can be coupled tofirst lateral module 206 in the x-direction 208 and second lateralmodule 210 in the y-direction 212 by respective male-to-femaleconnections 404. The male-to-female connections 404 can include engagingbi-directional couplings, as described below.

PV module assembly 200 can be connected to the external mounting surfaceby one or more brackets 406. Each bracket 406 can include an upper endmounted on support frame 402, and a lower end attached to the externalmounting surface. Bracket 406 can transmit a reaction force upward fromthe roof to support frame 402. The brackets 406 can be mounted on backsurface 314 inward from perimeter 218 extending around assembly 200.

Referring to FIG. 5 , a back view of a photovoltaic module havingbi-directional couplings is shown in accordance with an embodiment ofthe present disclosure. In an embodiment, support frame 402 mounted onback surface 314 of PV laminate 214 includes one or more support railsextending in orthogonal directions. For example, the horizontallyoriented support rails can include a first support rail 502 extendinglongitudinally in a first direction, e.g., x-direction 208, and a secondsupport rail 504 extending longitudinally in a second direction, e.g.,y-direction 212. The first direction can be orthogonal to the seconddirection, and thus, first support rail 502 can be orthogonal to secondsupport rail 504.

Each support rail can extend parallel to a side of perimeter 218. Forexample, the support rails can be mounted on perimeter 218 to form aperimeter frame (not shown). In an embodiment, the support rails arebacksheet-mounted inward from perimeter 218. More particularly, thesupport rails can be inset from corners 506 of PV module 202, as shownin FIG. 5 . The inset support rails can extend parallel to adjacentedges of PV module 202. For example, a first edge 508 of PV module 202can extend parallel to second support rail 504, and a second edge 510 ofPV module 202 can extend parallel to first support rail 502.

In an embodiment, support frame 402 includes at least two support railsextending in x-direction 208 and at least two support rails extending iny-direction 212. The two-axis rail system can have a hash profile, e.g.,resembling a hash tag. More particularly, the two-axis rail system caninclude inset crossing points 511 that form a grid over back surface 314of PV laminate 214. When support frame 402 includes two support rails inx-direction 208 and two support rails in y-direction 212, the grid has athree-by-three grid profile, similar to a profile of a tic-tac-toe grid.

Crossing points 511 of support frame 402 can be laterally inward fromcorners 506, and can be laterally outward from a central point 513 of PVlaminate 214. By way of example, back surface 314 can have quarterpoints 512, and crossing points 511 can be between a respective quarterpoint 512 and corner 506 a long a line radiating from central point 513.Each quarter point 512 can be defined as a center of a quadrant of backsurface 314. More particularly, the quarter point 512 in the upper-rightregion of PV laminate 214 in FIG. 5 can be separated from first edge 508of perimeter 218 by a distance equal to a module width divided by four.Similarly, the same quarter point 512 can be separated from second edge510 of perimeter 218 by a distance equal to a module height divided byfour. Accordingly, in the case of a square PV laminate 214, each quarterpoint 512 can be equidistant from central point 513 (at a center of PVlaminate 214) and a respective corner 506.

A distance between crossing points 511 can determine a distance betweenadjoined support rails, and thus, relates to a maximum unsupported spanof PV laminate 214. As such, crossing points 511 can be located tobalance an unsupported region in a central portion of the grid profileand an unsupported region laterally outward from the central portion. Inan embodiment, each crossing point 511 is located such that a diagonaldistance between crossing points 511, e.g., between the upper-rightcrossing point 511 and the lower-left crossing point 511, is in a rangeof 0.8-0.85 of a total length between opposite corners 506, e.g.,between the upper-right corner 506 and the lower-left corner 506. Itwill be appreciated that the description of quarter points 512 andcrossing points 511 is offered by way of example, and crossing points511 can be located anywhere along back surface 314 to provide abacksheet-mounted support structure for PV laminate 214.

Support rail segments extending between crossing points 511 can supportPV laminate 214 as an end-supported beam. By contrast, support railsegments laterally outward of crossing points 511 can support PVlaminate 214 as cantilever beams. A cantilever beam is stronger than anend supported beam so strength of support frame 402 can be increased bymoving crossing points 511 inboard from perimeter 218. Furtherenhancement of the cantilevered beam can be achieved by coupling eachcantilever beam portion of support frame 402 to an adjacent cantileverbeam portion of an adjacent PV module 202. To facilitate theseconnections, PV module 202 can include several couplings 520.

One or more couplings 520 can be mounted under each edge of PV module202. For example, perimeter 218 can have first edge 508 and second edge510, and second edge 510 can be orthogonal to first edge 508. In anembodiment, a first coupling 522 can be mounted on first support rail502, and a second coupling 524 can be mounted on second support rail504. For example, first coupling 522 of support frame 402 can be underfirst edge 508, and second coupling 524 of support frame 402 can beunder second edge 510. The couplings 520 can be mounted on supportrails, or can be integrally formed with support rails of support frame402. Support frame 402 of PV module 202, e.g., keystone module 204, caninclude additional couplings 520 along one or more edges. For example,third coupling 526 of support frame 402 can be under first edge 508, andfourth coupling 528 of support frame 402 can be under second edge 510.

In addition to PV laminate 214, support frame 402 can also supportcomponents attached to PV laminate 214. For example, electroniccomponents such as a microinverter 540, a junction box 542, poweroptimizer (e.g., a DC optimizer), and/or an electrical cable 544 can bemounted on back surface 314 of PV laminate 214. A weight of theelectronic components can be supported by support frame 402 under PVlaminate 214.

Weights and loading exerted on support frame 402 can be transmitted tothe external mounting surface through one or more bracket 406, asdescribed above. More particularly, each PV module 202 of PV moduleassembly 200 can include one or more brackets 406. Brackets 406 canattach anywhere along respective support rails. As shown, bracket 406can be mounted under first support rail of PV module 202. Similarly,additional brackets 406 can be mounted on first support rail 502 oranother support rail of support frame 402. For example, a bracket 406can be located at an optional bracket location 550 of a differentsupport rail.

A number of brackets 406 can vary from PV module to PV module in PVmodule assembly 200. For example, keystone module 204 can include afirst number of brackets 406, e.g., two or three brackets, and one ormore of first lateral module 206 or second lateral module 210 can have adifferent number of brackets 406, e.g., one bracket. In an embodiment,keystone module 204 has more brackets than the lateral modules becauseit is an initial module of PV module assembly 200. More particularly,keystone module 204 can be a first module mounted on the externalmounting surface, and thus, can be attached to the external mountingsurface by the more numerous first number of brackets 406 to space themodule apart from the roof. By contrast, subsequent modules, such asfirst lateral module 206 and second lateral module 210, can be attachedto the external mounting surface by the fewer second number of brackets(or third number of brackets). The number of brackets attaching thelateral modules to the external supporting surface can be fewer than thefirst number of brackets because the subsequent modules gain supportthrough their attachments to keystone module 204. More attachments canbe needed to stabilize the initial modules in the array, and fewerattachments can be needed subsequently.

Referring to FIG. 6 , a back view of a corner region of a photovoltaicmodule having bi-directional couplings is shown in accordance with anembodiment of the present disclosure. Each elongated support rail canextend between respective ends. For example, first support rail 502 canbe a rail segment extending longitudinally in first direction from afirst inward end 602 to a first outward end 604. Similarly, secondsupport rail 504 can be a rail segment extending longitudinally insecond direction from a second inward end 606 to a second outward end608.

The outward ends of each support rail can support respectivebi-directional couplings 520. For example, first coupling 522 can bemounted on first outward end 604, and second coupling 524 can be mountedon second outward end 608. Each coupling 520 can be attached to therespective outward end, and can extend laterally outward toward arespective coupling tip 610. For example, first coupling 522 can beattached to first outward end 604 laterally inward of perimeter 218, andfirst coupling 522 can extend to a coupling tip 610 laterally outward ofperimeter 218. Second coupling 524 can similarly extend from secondoutward end 608 (inward of perimeter 218) to a respective coupling tip610.

In an embodiment, inward ends of the support rails are interconnected bya rail coupler 612. For example, rail coupler 612 can couple firstsupport rail 502 to second support rail 504. First support rail 502 canextend between first outward end 604 and first inward end 602 at railcoupler 612, and second support rail 504 can extend between secondoutward end 608 and second inward end 606 at rail coupler 612. Railcoupler 612 can interconnect first inward end 602 to second inward end606. Similar rail couplers 612 can be located at each crossing point 511to connect individual segments of support frame 402. More particularly,the hash architecture of support frame 402 can be fabricated byinterconnecting rail segments at rail couplers 612. Rail coupler 612structure can be any structure that attaches fastens several railstogether. An example of a rail coupler 612 structure is described belowwith respect to FIG. 19 .

In an embodiment, PV module 202 and/or PV laminate 214 includes corner506 along perimeter 218. Corner 506 can be laterally outward of quarterpoint 512 at a location where first edge 508 and second edge 510 meet.More particularly, quarter point 512 can be laterally inward of corner506. As described above, rail coupler 612 can be located at crossingpoint 511 of support frame 402, and thus, rail coupler 612 can bemounted on PV laminate 214 laterally between quarter point 512 andcorner 506.

In an embodiment, PV module 202 includes an edge protector 614 mountedon corner 506. Edge protector 614 can be a molded polymer cover toprotect corner 506 of PV laminate 214 against impacts during shipmentand installation. As described below with respect to FIG. 21 , edgeprotector 614 can include vertical interlock features to maintain arelative lateral position between stacked PV modules 202 duringshipment.

Couplings 520 of PV module 202 are interleaving connecting pieces thatcan attach to each other to rapidly couple adjacent PV modules 202 inseveral directions. The attachments between couplings 520 can be anykind of mechanical fastening mechanism. For example, couplings 520 cansnap together and/or couplings 520 can assemble in a tongue-and-groovefashion. Such couplings 520 are described below, however, it will beappreciated that any mechanical fastening mechanism can be used tointerconnect keystone module 204 to first lateral module 206 inx-direction 208 and to second lateral module 210 in y-direction 212. Forexample, support frame 402 under keystone module 204 can be coupled tosupport frame 402 under first lateral module 206 by connecting a firstend of a tension rod to the keystone module frame and a second end ofthe tension rod to the lateral module frame. Accordingly, themale-to-female connections described below are illustrative andnon-limiting.

Referring to FIG. 7 , a perspective view of a male coupling is shown inaccordance with an embodiment of the present disclosure. A coupling 520,e.g., first coupling 522, can be a male coupling 702. Male coupling 702can be so-named because the coupling can engage a female coupling asdescribed below to form male-to-female connection 404.

In an embodiment, male coupling 702 includes a coupling base 704.Coupling base 704 can be a portion of male coupling 702 that mounts onfirst outward end 604. For example, a proximal end 706 of coupling base704 can be located adjacent to first outward end 604. A coupler insert708 can extend laterally from proximal end 706. Coupler insert 708 canbe mounted inside of a support rail. For example, first support rail 502can have a tubular structure as described below with respect to FIG. 20, and coupler insert 708 can be press fit or threaded into the tubularstructure to secure coupling base 704 to first outward end 604.

Male coupling 702 can include a tongue 710 extending laterally outwardfrom coupling base 704 to coupling tip 610. In an embodiment, tongue 710extends distally from coupling base 704. Tongue 710 can extend along acurvilinear path, as shown. More particularly, tongue 710 can arcforward from a tongue base 712 at coupling base 704 to coupling tip 610.In an embodiment, tongue 710 has several transversely separatedportions. More particularly, tongue 710 can have a first tongue portion714 separated from a second tongue portion 716 in a transverse directionby a coupling channel 718. Coupling channel 718 can be a vertical gapbetween first tongue portion 714 and second tongue portion 716. Couplingchannel 718 can be configured to receive a corresponding feature of afemale coupling, as described below.

In an embodiment, male coupling 702 includes several clip walls 720extending from tongue 710. For example, a first clip wall 720 can extendvertically downward from first tongue portion 714, and a second clipwall 720 can extend vertically downward from second tongue portion 716.

Referring to FIG. 8 , a side view of a male coupling is shown inaccordance with an embodiment of the present disclosure. Male coupling702 can include a cable management channel 802 to receive electricalcable(s) 544 mounted on PV laminate 214. For example, coupling base 704of male coupling 702 can include an upper surface 804 forming a recessbelow an uppermost horizontal plane. Cable management channel 802 can bewithin the recess between upper surface 804 and PV laminate 214 (notshown). Electrical cable 544 can extend through cable management channel802 to cross from one grid of back surface 314 on a first side of asupport rail to another grid on back surface 314 on an opposite side ofthe support rail. More particularly, upper surface 804 of coupling base704 can support cables being held within cable management channel 802.Electrical cable 544 can be electrically connected to PV cell 216 and/ormicroinverter 540 to carry electrical power along back surface 314.

Referring to FIG. 9 , a cross-sectional view, taken about line 9-9 ofFIG. 8 , of a male coupling is shown in accordance with an embodiment ofthe present disclosure.

Clip walls 720 extending from tongue portion 714, 716 can define a clipchannel 902 to receive a portion of a female coupling, as describedbelow. More particularly, clip channel 902 can be a gap between clipwalls 720 in a transverse direction to a longitudinal axis of malecoupling 702. Male coupling 702 can include clip teeth 904 extendingtransversely inward from clip walls 720 below clip channel 902. Clipteeth 904 include inward ledges to can hook around a correspondingfeature of a female coupling, e.g., around a locking knuckle, asdescribed below.

Referring to FIG. 10 , a top view of a male coupling is shown inaccordance with an embodiment of the present disclosure. The top viewshows that, in an embodiment, coupling channel 718 extendslongitudinally from a distal end 1002 of coupling base 704 to couplingtips 610 of first tongue portion 714 and second tongue portion 716.Tongue 710 is illustrated as having two portions, however, tongue 710can be a single longitudinally extending protrusion. More particularly,male coupling 702 may not include coupling channel 718 within tongue710. It will be appreciated, however, that splitting tongue 710 intoseveral portions allows male coupling 702 to receive a correspondingportion of a female coupling, as described below, which can increase analignment and rigidity of male-to-female connection 404 formed betweenmale coupling 702 on one PV module 202 and a female coupling on anotherPV module 202.

Referring to FIG. 11 , a perspective view of a female coupling is shownin accordance with an embodiment of the present disclosure. A coupling520, e.g., first coupling 522, can be a female coupling 1102. Femalecoupling 1102 can include some portions similar to the portions of malecoupling 702 described above. For example, female coupling 1102 caninclude coupling base 704 having proximal end 706. Coupling base 704 canbe mounted on first outward end 604, e.g., by inserting coupler insert708 into a receiving channel of first support rail 502.

In an embodiment, female coupling 1102 includes several receiving walls1103 extending from coupling base 704. More particularly, receivingwalls 1103 can be vertical walls separated in a transverse direction bya gap. The receiving walls 1103 can extend upward from a receiving floor1104. Receiving floor 1104 can extend transversely between walls 1103.Thus, the gap can provide a receiving channel 1106 between receivingwalls 1103 and above receiving floor 1104. In an embodiment, tongue 710of male coupling 702 can be inserted into receiving channel 1106. Moreparticularly, tongue 710 can slide over receiving floor 1104 to restwithin the channel between receiving walls 1103 of female coupling 1102.

In addition to having channels to receive corresponding features of malecoupling 702, female coupling 1102 can have features to insert intocorresponding features of male coupling 702. For example, femalecoupling 1102 can include an insert wall 1108 extending upward fromreceiving floor 1104 within channel 1106. Insert wall 1108 can insertinto coupling channel 718 when tongue 710 of male coupling 702 is loadedinto receiving channel 1106 of female coupling 1102.

In an embodiment, female coupling 1102 includes a locking knuckle 1110extending from receiving walls 1103. Locking knuckle 1110 can extendforward along a curvilinear path similar to the arcuate shape of tongue710. More particularly, locking knuckle 1110 can extend along an arcingprofile from a knuckle base 1112 to coupling tip 610.

Referring to FIG. 12 , a side view of a female coupling is shown inaccordance with an embodiment of the present disclosure. Female coupling1102 can include a cable management channel 802 to receive electricalcable(s) 544 mounted on PV laminate 214. For example, coupling base 704of female coupling 1102 can include a vertical recess in upper surface804, and cable management channel 802 can be between upper surface 804and PV laminate 214 (not shown).

Referring to FIG. 13 , a cross-sectional view, taken about line 13-13 ofFIG. 12 , of a female coupling is shown in accordance with an embodimentof the present disclosure. Receiving walls 1103 extending from receivingfloor 1104 define receiving channel 1106 to receive a tongue portion ofmale coupling 702. More particularly, receiving channel 1106 can includeone or more gaps between receiving walls 1103 in a transverse directionrelative to a longitudinal axis of female coupling 1102. Receivingchannel 1106 can include a first gap between a leftward receiving wall1103 and insert wall 1108, and a second gap between a rightwardreceiving wall 1103 and insert wall 1108. The first gap can receivefirst tongue portion 714, and the second gap can receive second tongueportion 716. Female coupling 1102 can include clip teeth 904 extendingtransversely inward from receiving walls 1103 above receiving channel1106. Clip teeth 904 can include inward ledges to hook around acorresponding feature of a male coupling 702, e.g., around tongue 710.

Referring to FIG. 14 , a top view of a female coupling is shown inaccordance with an embodiment of the present disclosure. The top viewshows that, in an embodiment, receiving channel 1106 extendslongitudinally from coupling tip 610 to intersect cable managementchannel 802. More particularly, receiving channel 1106 extendslongitudinally over receiving floor 1104 to allow tongue 710 of malecoupling 702 to insert into receiving channel 1106 and slide overreceiving floor 1104 and under clip teeth 904 of female coupling 1102.Thus, when male coupling 702 is engaged with female coupling 1102, amale-to-female connection 404 is formed.

Referring to FIG. 15A, a male coupling connecting to a female couplingusing a first locking mode is shown in accordance with an embodiment ofthe present disclosure. The first locking mode can be a tongue andgroove locking mechanism. More particularly, the locking mechanism caninvolve tongue 710 of male coupling 702 sliding into receiving channel1106 of female coupling 1102. In an embodiment, keystone module 204includes female coupling 1102 and first lateral module 206 includes malecoupling 702. Tongue 710 of male coupling 702 can be lowered intoreceiving channel 1106, e.g., onto receiving floor 1104 of femalecoupling 1102. First lateral module 206 can be inserted at an angle suchthat a longitudinal axis extending through a support rail of firstlateral module 206 is oblique to a longitudinal axis extending through asupport rail of keystone module 204.

Referring to FIG. 15B, tongue 710 can hook under clip teeth 904 (hidden)of female coupling 1102. Accordingly male coupling 702 can engage femalecoupling 1102. The engagement between the couplings 520 can include apivoting relationship between tongue 710 and clip teeth 904. That is,first lateral module 206 can be raised or lowered to change an anglebetween the respective lateral planes of respective PV laminates 214.

Referring to FIG. 15C, when first lateral module 206 is lowered suchthat respective lateral planes 310 are parallel in a horizontaldirection, clip walls 720 of male coupling 702 can extend around lockingknuckle 1110 of female coupling 1102. For example, clip teeth 904 onclip walls 720 can slide around an outside of locking knuckle 1110,causing clip walls 720 to flex outward until the ledges of clip teeth904 are lower than a ridgeline of locking knuckle 1110. When the clipteeth 904 are below the ridgeline, clip walls 720 can flex inward tosecure the ledges of clip teeth 904 under locking knuckle 1110.Accordingly, when male coupling 702 forms male-to-female connection 404with female coupling 1102, tongue 710 can be mounted on locking knuckle1110, and coupling tip 610 of male coupling 702 can be in receivingchannel 1106 of female coupling 1102. Furthermore, clip walls 720 ofmale coupling 702 can extend from tongue 710 around locking knuckle 1110of female coupling 1102. Thus, male coupling 702 can snap onto femalecoupling 1102 to form an interconnection between keystone module 204 andfirst lateral module 206.

Referring to FIG. 16A, a male coupling connecting to a female couplingusing a second locking mode is shown in accordance with an embodiment ofthe present disclosure. The second locking mode can be a snap lockingmechanism. More particularly, the locking mechanism can involve malecoupling 702 lowering onto and snapping over female coupling 1102. In anembodiment, keystone module 204 includes female coupling 1102 and alateral PV module 202 includes male coupling 702. Tongue 710 of malecoupling 702 can be lowered over insert wall 1108 of female coupling1102. More particularly, the lateral PV module 202 can pivot about afirst male-to-female connection 404 to cause the lateral plane 310 ofthe lateral PV module 202 to parallel the lateral plane 310 of keystonemodule 204.

Referring to FIG. 16B, as the lateral PV module 202 lowers, clip walls720 of male coupling 702 can extend around locking knuckle 1110 offemale coupling 1102. For example, clip teeth 904 on clip walls 720 canslide around an outside of locking knuckle 1110, causing clip walls 720to flex outward until the ledges of clip teeth 904 are lower than aridgeline of locking knuckle 1110. When the clip teeth 904 are below theridgeline, clip walls 720 can flex inward to secure the ledges of clipteeth 904 under locking knuckle 1110. Accordingly, male coupling 702 ofthe lateral PV module 202 can snap onto female coupling 1102 of keystonemodule 204 to form an interconnection between keystone module 204 andthe lateral PV module 202.

It will be appreciated that, although male-to-female connection 404 canbe achieved by different locking mechanisms, e.g., via tongue and groovelocking or snap locking, the interconnection between adjacent PV modules202 can be stiff and rigid. Interference between portions of malecoupling 702 and female coupling 1102 can provide stability. Forexample, clip walls 720 snapped around locking knuckle 1110 can providerotational stability about the longitudinal axis passing through thejoined support rails. Similarly, receiving walls 1103 extending aroundtongue 710 can provide rotational stability. Receiving walls 1103 andinsert wall 1108 also provide lateral stability to the joint. Forexample, tongue 710 remains stabilized, within receiving channel 1106,in a transverse direction relative to the longitudinal axis. Axialstability, e.g., stability in the longitudinal direction is provided byinterference between locking knuckle 1110 and tongue 710. Moreparticularly, the arcuate profiles of tongue 710 and locking knuckle1110 can interfere to limit axial movement of male coupling 702 relativeto female coupling 1102 after the couplings are snapped together.Accordingly, male-to-female connections 404 formed by engagement betweenmale coupling 702 and female coupling 1102 can be stable and rigid.

Referring to FIG. 17 , a flowchart of a method of assembling aphotovoltaic module assembly having bi-directionally connectedphotovoltaic modules is shown in accordance with an embodiment of thepresent disclosure. FIGS. 18A-18C illustrate operations in the method ofFIG. 17 , and thus, FIGS. 17-18C are described in combination below.

At operation 1702, keystone module 204 is attached to an externalsupport structure, e.g., a roof. As described above, keystone module 204can be attached to the external support structure by a first number ofbrackets 406. For example, two brackets can be used to attach supportframe 402 of keystone module 204 to the roof.

At operation 1704, first lateral module 206 is attached to firstcoupling 522 of keystone module 204. Referring to FIG. 18A, firstlateral module 206 can be coupled to keystone module 204 using a tongueand groove locking mechanism (FIGS. 15A-15C). Accordingly, firstcoupling 522 can be under first edge 508 of keystone module 204, and canreceive a corresponding coupling 520 on first lateral module 206. Forexample, first lateral module 206 can include a male coupling 702 havingtongue 710, and first coupling 522 can be female coupling 1102 having areceiving channel 1106 between receiving walls 1103. Tongue 710 can beinserted into receiving channel 1106 to attach first lateral module 206to first coupling 522.

In an embodiment, keystone module 204 includes first coupling 522 andthird coupling 526, and both first coupling 522 and third coupling 526are female couplings 1102. Accordingly, first lateral module 206 caninclude a pair of male couplings 702 to engage the pair of femalecouplings 1102 on keystone module 204. The male couplings 702 of firstlateral module 206 can be mounted on the female couplings 1102 ofkeystone module 204.

At operation 1706, second lateral module 210 is attached to secondcoupling 524 of keystone module 204. Referring to FIG. 18B, secondlateral module 210 can be coupled to keystone module 204 using a tongueand groove locking mechanism (FIGS. 15A-15C). Accordingly, secondcoupling 524 can be under second edge 510 of keystone module 204orthogonal to first edge 508, and can receive a corresponding coupling520 on second lateral module 210. For example, second lateral module 210can include a male coupling 702 having tongue 710, and second coupling524 can be female coupling 1102 having a receiving channel 1106 betweenreceiving walls 1103. Tongue 710 can be inserted into receiving channel1106 to attach second lateral module 210 to second coupling 524.

In an embodiment, keystone module 204 includes second coupling 524 andfourth coupling 528, and both second coupling 524 and fourth coupling528 are male couplings 702. Accordingly, second lateral module 210 caninclude a pair of female couplings 1102 to engage the pair of malecouplings 702 on keystone module 204. More particularly, the femalecouplings 1102 of second lateral module 210 can be mounted on the malecouplings 702 of keystone module 204.

Each PV module 202 of PV module assembly 200 can be separated from anadjacent module by a gap. For example, PV module assembly 200 caninclude a first gap 1802 between first edge 508 of keystone module 204and an adjacent edge of first lateral module 206. Similarly, PV moduleassembly 200 can include a second gap 1804 between second edge 510 ofkeystone module 204 and an adjacent edge of second lateral module 210.The male-to-female connections 404, however, allow adjacent PV modules202 to be mounted closely together. That is, the tongue and grooveconnection scheme described above permits an adjacent module to rock orpivot into place next to an adjoining module. The gaps between modulescan be on an order of less than 100 mm. for example, first gap 1802 andsecond gap 1804 can have respective gap distances between module edgeswithin a range of 1-10 mm, e.g., 3-4 mm.

At operation 1708, first lateral module 206 is attached to the externalsupport structure. First lateral module 206 can be attached to the roofby a second number of brackets. At operation 1710, second lateral module210 is attached to the external support structure. Second lateral module210 can be attached to the roof by a third number of brackets. In anembodiment, the first number of brackets attaching keystone module 204to the roof is more than the second number of brackets and the thirdnumber of brackets. For example, first lateral module 206 and secondlateral module 210 can be attached to the roof by a single respectivebracket.

Referring to FIG. 18C, PV module assembly 200 can include a terminalmodule 1806 attached to first lateral module 206 and second lateralmodule 210. Terminal module 1806 can connect to first lateral module 206and second lateral module 210 along two axes using an underlying supportframe 402. More particularly, the support frame 402 of terminal module1806 can connect to first lateral module 206 along a lower edge, and thesupport frame 402 of terminal module 1806 can connect to second lateralmodule 210 along a left edge. In an embodiment, terminal module 1806attaches to first lateral module 206 using a tongue and groove lockingmechanism (FIGS. 15A-15C), and terminal module 1806 attaches to secondlateral module 210 using a snap locking mechanism (FIGS. 16A-16B). Thedifferent locking mechanisms can allow couplings 520 of terminal module1806 along the lower edge to engage first lateral module 206 at an angleand then be lowered down to drop couplings 520 of terminal module 1806along the left edge onto corresponding couplings of second lateralmodule 210. When terminal module 1806 is flat, e.g., when all lateralplanes 310 of PV module assembly 200 are parallel to each other, the PVmodules 202 can be snapped together to form a rigidly connected moduleassembly. The PV module assembly 200 can distribute loading throughoutthe array structure, including distributing vertical loading applied tothe roof at bracket attachments. As such, mounting points for the PVmodules 202 can be distributed optimally over an entire area of themodule array, and loading on each PV module 202 can be shared withadjacent PV modules 202.

Referring to FIG. 19 , a perspective view of a rail coupler is shown inaccordance with an embodiment of the present disclosure. Rail coupler612 can join one or more support rails. For example, rail coupler 612can include a first coupler prong 1902 to attach to first support rail502, and a second coupler prong 1904 to attach to second support rail504. First coupler prong 1902 can extend orthogonal to second couplerprong 1904. Rail coupler 612 can have a tee shape, and thus, firstcoupler prong 1902 can extend across a central axis passing through acenter of rail coupler 612 to an opposite prong end. Similarly, secondcoupler prong 1904 can extend across the central axis to an oppositeprong end. In an embodiment, the opposite prong ends can be ends ofadditional coupler prongs, e.g., a third coupler prong 1906 and a fourthcoupler prong 1908. Accordingly, the tee-shaped rail coupler 612 canengage inward ends of several support rails and/or support rail segmentsof support frame 402. To engage, the prongs can be inserted into atubular channel of the support rail(s).

Referring to FIG. 20 , a cross-sectional view of a support rail is shownin accordance with an embodiment of the present disclosure. Supportrails of support frame 402 can be tubular. For example, first supportrail 502 can include a longitudinal channel 2002 within a rail wall2004. Rail wall 2004 can be a cylindrical tubular wall, a rectangulartubular wall, or any other shape of tubular wall. In an embodiment, thesupport rail can have a cross-sectional area that includes an upperflange 2006 and a lower flange 2008. The flanges give the support railan I-beam shape. The I-beam shaped tube can be hollow, e.g., arectangular longitudinal channel 2002 can extend longitudinally throughthe I-beam shaped tube.

In an embodiment, rail coupler 612 is inserted into longitudinal channel2002 to secure rail coupler 612 to support frame 402. For example, firstcoupler prong 1902 of first coupling 522 can be mounted in longitudinalchannel 2002 of first support rail 502 to attach first coupler prong1902 to first inward end 602. Similarly, second coupler prong 1904 canbe inserted into another longitudinal channel 2002 of second supportrail 504 to attach second coupler prong 1904 to second inward end 606.Accordingly, longitudinal channel 2002 can be a receptacle to receiverail coupler 612 for joining the support rail to another support rail.

In an embodiment, support rails can be adhered to PV laminate 214. Forexample, an adhesive material, such as a glue or and encapsulantmaterial, can be disposed between the support rail and back surface 314.Alternatively, support rails can be attached to PV laminate 214 bymechanical fasteners such as screws, rivets, clips, etc.

Referring to FIG. 21 , a perspective view of a corner region of aphotovoltaic module having a stackable edge protector is shown inaccordance with an embodiment of the present disclosure. Edge protector614 can have an internal recess to receive corner 506 of PV laminate214. Edge protector 614 can be fabricated from a shock resistantmaterial, and thus, can protect PV laminate 214 during shipping and/orinstallation.

In an embodiment, edge protector 614 includes one or more verticalinterlock features 2102. For example, vertical interlock feature 2102can be a vertical boss 2104 extending upward from a top surface of edgeprotector 614. Alternatively, vertical interlock feature 2102 can be avertical recess 2106 extending downward from the top surface of edgeprotector 614. Vertical interlock features 2102 can engage each otherwhen PV modules 202 are stacked. More particularly, an edge protector614 on the corner 506 of a first stacked module can mesh with an edgeprotector 614 on the corner 506 of a second stacked module. Verticalbosses 2104 of one edge protector 614 can engage vertical recesses 2106of another edge protector 614. Vertical bosses 2104 can be nested withinvertical recesses 2106 such that lateral movement is resisted. When alateral load is applied to the first stacked module, mechanicalinterference between vertical bosses 2104 and vertical recesses 2106 canprevent the first stacked module from moving laterally relative to thesecond stacked module.

The components of PV module 202 can be fabricated from variousmaterials. For example, support rails and/or rail couplers 612 can befabricated from aluminum, e.g., die-cast aluminum. By contrast, edgeprotector 614 can be fabricated from a polymer, e.g., a molded polymer.Such material choices are offered by way of example, however, and thecomponents can be formed from different materials. For example, railcouplers 612 can be fabricated from a polymer.

A PV module having bi-directional couplings is described. Althoughspecific embodiments have been described above, these embodiments arenot intended to limit the scope of the present disclosure, even whereonly a single embodiment is described with respect to a particularfeature. Examples of features provided in the disclosure are intended tobe illustrative rather than restrictive unless stated otherwise. Theabove description is intended to cover such alternatives, modifications,and equivalents as would be apparent to a person skilled in the arthaving the benefit of this disclosure.

The scope of the present disclosure includes any feature or combinationof features disclosed herein (either explicitly or implicitly), or anygeneralization thereof, whether or not it mitigates any or all of theproblems addressed herein. Accordingly, new claims may be formulatedduring prosecution of this application (or an application claimingpriority thereto) to any such combination of features. In particular,with reference to the appended claims, features from dependent claimsmay be combined with those of the independent claims and features fromrespective independent claims may be combined in any appropriate mannerand not merely in the specific combinations enumerated in the appendedclaims.

What is claimed is:
 1. A photovoltaic module system comprising: a firstphotovoltaic laminate; and a second photovoltaic laminate; wherein eachof the first and second photovoltaic laminates has a perimeter and asupport frame mounted on a back surface of the laminate, the supportframe positioned completely within the perimeter of the associated firstor second photovoltaic laminate, wherein each support frame of the firstand second photovoltaic laminates comprises a plurality of support framemembers, wherein at least two of the support frame members of the firstand second photovoltaic laminates intersect and form cantilevered endsextending past their intersection, the cantilevered ends each having afirst distal end, and wherein the first distal end of the support framemember from the first photovoltaic laminate is coupled to the firstdistal end of the support frame member from the second photovoltaiclaminate with a first mechanical coupling pair from a plurality ofmechanical coupling pairs.
 2. The photovoltaic module system of claim 1wherein the first mechanical coupling pair includes a male coupling anda female coupling.
 3. The photovoltaic module system of claim 2 whereinthe male mechanical coupling comprises a forked tongue, the forkedtongue comprising two separated tongue portions, each separated tongueportion ending in a coupling tip.
 4. The photovoltaic module system ofclaim 3 wherein the female mechanical coupling comprises two receivingchannels, the receiving channels spaced apart from each other and sizedand shaped to each receive at least a coupling tip from one of theseparated tongue portions of the male mechanical coupling.
 5. Thephotovoltaic module system of claim 2 wherein the male mechanicalcoupling is secured to the female mechanical coupling with a forkedtongue distal end of the male mechanical coupling positioned withinreceiving walls of the female mechanical coupling.
 6. The photovoltaicmodule system of claim 1 further comprising: a third photovoltaiclaminate; and a fourth photovoltaic laminate, wherein each of the thirdand fourth photovoltaic laminates has a perimeter and a support framemounted on a back surface of the laminate, the support frame positionedcompletely within the perimeter of the associated third or fourthphotovoltaic laminate, wherein each support frame of the third andfourth photovoltaic laminates comprises a plurality of support framemembers, wherein at least two of the support frame members of the thirdand fourth photovoltaic laminates intersect and form cantilevered endsextending past their intersection, the cantilevered ends each having adistal end, and wherein the distal end of the support frame member fromthe third photovoltaic laminate is coupled to the distal end of thesupport frame member from the fourth photovoltaic laminate with a secondmechanical coupling pair from the plurality of mechanical couplingpairs.
 7. The photovoltaic module system of claim 6 wherein a shape andsize of the first mechanical coupling pair and the shape and size of thesecond mechanical coupling pair mimic each other.
 8. A photovoltaicmodule system comprising: a first photovoltaic laminate; and a secondphotovoltaic laminate; wherein each of the first and second photovoltaiclaminates has a perimeter and a support frame mounted on a back surfaceof the laminate, wherein each support frame comprises a plurality ofsupport frame members, wherein at least two of the support frame membersof each photovoltaic laminate intersect and form cantilevered endsextending past their intersection, the cantilevered ends each having adistal end, and wherein the distal end of the support frame member fromthe first photovoltaic laminate is coupled to the distal end of asupport frame member from the second photovoltaic laminate with abi-directional mechanical coupling pair, the mechanical coupling paircomprising a male mechanical coupling with a tongue that extends beyondthe perimeter of the first photovoltaic laminate.
 9. The photovoltaicmodule system of claim 8 wherein the bi-directional mechanical couplingpair comprises the male mechanical coupling and a female mechanicalcoupling.
 10. The photovoltaic module system of claim 9 wherein thetongue of the male mechanical coupling is forked.
 11. The photovoltaicmodule system of claim 9 wherein the female mechanical couplingcomprises two receiving channels separated by an insert wall and a cablemanagement recess forming a channel through the receiving channels andthe insert wall.
 12. The photovoltaic module system of claim 9 whereinthe female mechanical coupling comprises two receiving channelsseparated by an insert wall.
 13. The photovoltaic module system of claim9 wherein a distal end of the female mechanical coupling comprises alocking knuckle.
 14. A photovoltaic module system comprising: a firstphotovoltaic laminate; a second photovoltaic laminate; a thirdphotovoltaic laminate; and a fourth photovoltaic laminate, wherein eachof the first, second, third and fourth photovoltaic laminates has aperimeter and a support frame mounted on a back surface of the laminate,the support frame positioned completely within the perimeter of theassociated first or second or third or fourth photovoltaic laminate,wherein each support frame of the first, second, third and fourthphotovoltaic laminates comprises a plurality of support frame members,wherein at least two of the support frame members of the first, second,third and fourth photovoltaic laminates have a distal end extending froma cantilevered portion of the support frame member, and wherein thedistal end extending from a cantilevered portion of the support framemember comprises a first mechanical coupling or a second mechanicalcoupling of a pair of mechanical couplings.
 15. The photovoltaic modulesystem of claim 14 wherein during assembly the first photovoltaiclaminate, the second photovoltaic laminate and the third photovoltaiclaminate are connected to each other in a planar fashion via pairs offirst male mechanical coupling and second female mechanical couplingsprior to the connection of the fourth photovoltaic laminate to the firstphotovoltaic laminate and the third photovoltaic laminate via pairs offirst male mechanical coupling and second female mechanical coupling.16. The photovoltaic module system of claim 15 wherein the first malemechanical coupling includes a forked tongue at a distal end.
 17. Thephotovoltaic module system of claim 14 wherein the perimeter isrectangular.
 18. The photovoltaic module system of claim 14 wherein thefirst mechanical coupling includes a coupler insert at a proximal end ofthe first mechanical coupling, the coupler sized and shaped to secure toa support frame member.
 19. The photovoltaic module system of claim 14wherein the first mechanical coupling and the second mechanical couplingeach comprise a cable management channel oriented across a width of thefirst mechanical coupling and a width of the second mechanical coupling.20. The photovoltaic module system of claim 19 wherein the cablemanagement channel has an oblong configuration.